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machining time problems (1)

The document outlines various machining operations including face milling, end milling, drilling, and turning, detailing parameters such as dimensions, cutting speeds, feeds, and depths of cut. Each operation requires calculations for machining time, taking into account approach and overtravel distances. The document provides specific scenarios for different materials and tools, emphasizing the importance of precise measurements and calculations in machining processes.

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surya Harsha
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37 views8 pages

machining time problems (1)

The document outlines various machining operations including face milling, end milling, drilling, and turning, detailing parameters such as dimensions, cutting speeds, feeds, and depths of cut. Each operation requires calculations for machining time, taking into account approach and overtravel distances. The document provides specific scenarios for different materials and tools, emphasizing the importance of precise measurements and calculations in machining processes.

Uploaded by

surya Harsha
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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1.

A square billet of 50 mm  50 mm having a length of 500 mm is being face milled along its
length with a cutter having diameter of 200 mm and 12 teeth. The cutter is rotating at 250
rpm. The feed per tooth is 0.10 mm/tooth and the axial depth of cut is 5 mm. Determine the
machining time considering approach and overlength each 10 mm.
2. A straight through slot of 200 mm long, 10 mm wide, and 3 mm deep is required to cut on a
metallic sample by end-milling operation in a single pass. The cutter has 10 mm diameter and
8 cutting edges. The table is fed at 0.02 mm/tooth, while a velocity of 60 m/min is employed.
Assume 2.5 mm approach and 2.5 mm overtravel. Calculate the machining time for this
operation.
3. A through hole is required to drill on a 75 mm thick plate using a two-flute HSS twist drill.
The drill diameter is 25 mm and its helix angle is 30° and cone angle is 118°. Cutting velocity
of 40 m/min and feed of 0.10 mm/flute are employed. Assume an approach of 4 mm and
overrun of 2 mm. Calculate machining time.
4. Straight turning of a steel bar of 800 mm length and 100 mm diameter is carried out at
0.1 mm/rev feed, 1.0 mm depth of cut, and 90 m/min velocity. Assume approach and
overtravel to be 10 mm and 2 mm, respectively. If the idle time is 1.0 minute and tool
change time is 2 minutes, calculate the cycle time per pass considering tool life of 15
minutes.

5. A through hole of diameter 25 mm is required to drill on a 75 mm thick plate using a


two-flute 30° helix angle and 118° cone angle HSS drill. Cutting velocity of 40 m/min
and feed of 0.10 mm/flute are employed. Assume an approach of 4 mm and overrun
of 2 mm. Calculate actual machining time in seconds.
7 A pre-forged bar of length of 500 mm is being taper turned in a CNC lathe with a constant cutting
 100 mm

speed of 100 m/min with a depth of cut of 2 mm at a feed of 0.2 mm/rev. Assume overtravel and approach to be
zero. Calculate the machining time. 20
0
m
m

500 mm
8. A circular disc (of 75 mm thickness) of low carbon steel of inner and outer diameter of 20
mm and 200 mm respectively is being faced in a CNC turning centre (lathe) at a constant
cutting velocity of 90 m/min at a feed of 0.2 mm/rev and depth of cut of 2 mm. Determine
the machining time for a single pass assuming approach and overtravel to be zero.
9. A circular disc of 200 mm diameter and 50 mm internal diameter is being faced in a centre
lathe at a cutting speed of 100 m/min. The spindle speed has been set with respect to the outer
diameter. The depth of cut and the feed are 1 mm and 0.1 mm/rev. Neglect approach and overtravel.

(i) Calculate machining or cutting time.

(ii) Also calculate the machining or cutting time if the same facing operation is undertaken in a CNC
lathe with constant cutting velocity of 100 m/min without changing the depth of cut and feed.

(iii) Calculate material removal rate and volume of material removal for facing in a CNC lathe

(iv) Determine the ratio of volume of material removal to the material removal rate and comment by
comparing your answer with the answer of Q.6(ii).

10. A 200 mm diameter circular bar is to be reduced to 196 mm by turning in a single pass with a
depth of cut of 2 mm. The length of the bar is 1000 mm. Assume: cutting velocity 120 m/min, feed
0.25 mm/rev, tool changing time 4 min, tool life 15 min, and idle time 2 min. Determine the cycle
time or cutting time per piece.

11. A plate of low carbon steel of 30 mm thickness is being drilled with a HSS twist drill of 10 mm
diameter at a cutting velocity of 20 m/min. The material removal rate is 4000 mm 3/min. Determine
the machining time per piece or cycle time, if tool life, idle time and tool change time are 40 min, 0.25
min and 1.5 min, respectively. Assume approach and over-travel to be 5 mm each.

12. A rectangular slot of 10 mm width and 200 mm length is being end milled (10 mm diameter) in a plate
at cutting velocity of 60 m/min. It is a four fluted solid carbide end mill. The feed and (axial) depths of
cut are 0.1 mm/flute and 1 mm, respectively. Calculate (i) feed rate, (ii) material removal rate and (iii)
machining time. Assume approach and over-travel to be 5 mm each.

13. An 80 mm wide and 500 mm long billet is being face milled by a 200 mm diameter and 100
mm long cutter having 12 teeth. The cutting speed is 120 m/min. The feed is 0.1 mm/tooth.
Determine the machining time per pass if approach and over-travel are 5 mm each.

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